OPERATOR’S MANUAL
FIXED BASE ROUTER
DOUBLE INSULATED
R163
Your router has been engineered and manufactured to our high standard for dependability, ease of operation, and operator
safety. When properly cared for, it will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator's manual before using
this product.
Thank you for your purchase.
SAVE THIS MANUAL FOR FUTURE REFERENCE
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GENERAL SAFETy RULES
Remove any adjusting key or wrench before turning
the power tool on. A wrench or a key left attached to
a rotating part of the power tool may result in personal
injury.
WARNING!
Read all instructions. Failure to follow all instructions
listed below may result in electric shock, fire and/or
serious injury. The term “power tool” in all of the warn-
ings listed below refers to your mains-operated (corded)
power tool or battery-operated (cordless) power tool.
Do not overreach. keep proper footing and balance
at all times. This enables better control of the power tool
in unexpected situations.
Dress properly. Do not wear loose clothing or jewelry.
keep your hair, clothing and gloves away from moving
parts. Loose clothes, jewelry or long hair can be caught
in moving parts.
If devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. Use of these devices can
reduce dust-related hazards.
Do not wear loose clothing or jewelry. Contain long
hair. Loose clothes, jewelry, or long hair can be drawn
into air vents.
SAVE THESE INSTRUCTIONS
WORk AREA SAFETy
keep work area clean and well lit. Cluttered or dark
areas invite accidents.
Do not operate power tools in explosive atmo-
spheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks which
may ignite the dust or fumes.
Do not use on a ladder or unstable support. Stable
footing on a solid surface enables better control of the
power tool in unexpected situations.
keep children and bystanders away while operating a
power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETy
POWER TOOL USE AND CARE
Power tool plugs must match the outlet. Never modify
the plug in any way. Do not use any adapter plugs with
earthed (grounded) power tools. Unmodified plugs and
matching outlets will reduce risk of electric shock.
Do not force the power tool. Use the correct power tool
for your application. The correct power tool will do the job
better and safer at the rate for which it was designed.
Do not use the power tool if the switch does not turn
it on and off. Any power tool that cannot be controlled
with the switch is dangerous and must be repaired.
Disconnect the plug from the power source and/or
the battery pack from the power tool before making
any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce
the risk of starting the power tool accidentally.
Store idle power tools out of the reach of children and
do not allow persons unfamiliar with the power tool
or these instructions to operate the power tool. Power
tools are dangerous in the hands of untrained users.
Maintain power tools. Check for misalignment or bind-
ing of moving parts, breakage of parts and any other
condition that may affect the power tool’s operation.
If damaged, have the power tool repaired before use.
Many accidents are caused by poorly maintained power
tools.
Avoid body contact with earthed or grounded surfaces
such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body
is earthed or grounded.
Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of elec-
tric shock.
Do not abuse the cord. Never use the cord for carrying,
pulling or unplugging the power tool. keep cord away
from heat, oil, sharp edges or moving parts. Damaged
or entangled cords increase the risk of electric shock.
When operating a power tool outdoors, use an exten-
sion cord suitable for outdoor use. Use of a cord suit-
able for outdoor use reduces the risk of electric shock.
PERSONAL SAFETy
Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under the
influence of drugs, alcohol or medication. A moment
of inattention while operating power tools may result in
serious personal injury.
Use safety equipment. Always wear eye protection.
Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for appropri-
ate conditions will reduce personal injuries.
keep cutting tools sharp and clean. Properly main-
tained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
Use the power tool, accessories and tool bits etc., in
accordance with these instructions and in the manner
intended for the particular type of power tool, taking
into account the working conditions and the work to
be performed. Use of the power tool for operations dif-
ferent from those intended could result in a hazardous
situation.
Avoid accidental starting. Ensure the switch is in the
off-position before plugging in. Carrying power tools
with your finger on the switch or plugging in power tools
that have the switch on invites accidents.
3
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GENERAL SAFETy RULES
SERVICE
Whenservicingapowertool,useonlyidenticalreplace-
mentparts.FollowinstructionsintheMaintenancesec-
tion of this manual. Use of unauthorized parts or failure to
follow Maintenance instructions may create a risk of
shock or injury.
Have your power tool serviced by a qualified repair
person using only identical replacement parts. This will
ensure that the safety of the power tool is maintained.
WARNING!
To reduce the risk of injury, user must read instruction
manual.
SPECIFIC SAFETy RULES
Hold power tools by insulated gripping surfaces when
performing an operation where the cutting tool may
contact hidden wiring or its own cord. Contact with a
“live” wire will make exposed metal parts of the tool “live”
and shock the operator.
Check damaged parts. Before further use of the power
tool, a guard or other part that is damaged should be
carefully checked to determine that it will operate
properly and perform its intended function. Check for
alignment of moving parts, binding of moving parts,
breakage of parts, mounting, and any other conditions
that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced
by an authorized service center. Following this rule will
reduce the risk of shock, fire, or serious injury.
Use clamps or another practical way to secure and
support the workpiece to a stable platform. Holding
the work by hand or against your body leaves it unstable
and may lead to loss of control.
Bits coast after router has been turned off.
Make sure your extension cord is in good condi-
tion. When using an extension cord, be sure to use
one heavy enough to carry the current your product
will draw. A wire gauge size (A.W.G.) of at least 14 is
recommended for an extension cord 50 feet or less
in length. A cord exceeding 100 feet is not recom-
mended. If in doubt, use the next heavier gauge. The
smaller the gauge number, the heavier the cord. An
undersized cord will cause a drop in line voltage resulting
in loss of power and overheating.
know your power tool. Read operator’s manual care-
fully. Learn its applications and limitations, as well as
the specific potential hazards related to this power
tool. Following this rule will reduce the risk of electric
shock, fire, or serious injury.
Always wear safety glasses. Everyday eyeglasses
have only impact-resistant lenses; they are NOT safety
glasses. Following this rule will reduce the risk of serious
personal injury.
Protect your lungs. Wear a face or dust mask if the
operation is dusty. Following this rule will reduce the risk
of serious personal injury.
Inspect for and remove all nails from lumber before
using this power tool. Following this rule will reduce the
risk of serious personal injury.
Protect your hearing. Wear hearing protection during
extended periods of operation. Following this rule will
reduce the risk of serious personal injury.
Ifthepowersupplycordisdamaged,itmustbereplaced
only by the manufacturer or by an authorized service
center to avoid risk.
Inspect power tool cords periodically and, if damaged,
have repaired at your nearest Authorized Service Cen-
ter. Constantly stay aware of cord location. Following
this rule will reduce the risk of electric shock or fire.
Save these instructions. Refer to them frequently and
use them to instruct others who may use this power tool.
If you loan someone this power tool, loan them these
instructions also.
4
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SyMBOLS
Someofthefollowingsymbolsmaybeusedonthistool. Pleasestudythemandlearntheirmeaning. Properinterpretation
of these symbols will allow you to operate the tool better and safer.
SyMBOL
NAME
DESIGNATION/EXPLANATION
V
Volts
Voltage
Current
A
Hz
W
Amperes
Hertz
Frequency (cycles per second)
Power
Watt
min
Minutes
Time
Alternating Current
Direct Current
Type of current
Type or a characteristic of current
Rotational speed, at no load
Double-insulated construction
Revolutions, strokes, surface speed, orbits etc., per minute
n
o
No Load Speed
Class II Construction
Per Minute
.../min
Wet Conditions Alert
Do not expose to rain or use in damp locations.
To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Read The Operator’s Manual
Always wear safety goggles or safety glasses with side shields and,
as necessary, a full face shield when operating this product.
Eye Protection
Safety Alert
Precautions that involve your safety.
Failure to keep your hands away from the blade will result in serious
personal injury.
No Hands Symbol
Failure to keep your hands away from the blade will result in serious
personal injury.
No Hands Symbol
No Hands Symbol
No Hands Symbol
Failure to keep your hands away from the blade will result in serious
personal injury.
Failure to keep your hands away from the blade will result in serious
personal injury.
To reduce the risk of injury or damage, avoid contact with any hot
surface.
Hot Surface
5
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SyMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SyMBOL
SIGNAL
MEANING
Indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
DANGER:
Indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
WARNING:
CAUTION
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, may result in
minor or moderate injury.
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SERVICE
WARNING:
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the product to the nearest
AUTHORIZED SERVICE CENTER for repair. When servic-
ing, use only identical replacement parts.
To avoid serious personal injury, do not attempt to use this
product until you read thoroughly and understand com-
pletely the operator’s manual. If you do not understand
the warnings and instructions in the operator’s manual,
do not use this product. Call Ryobi customer service for
assistance.
WARNING:
The operation of any power tool can result in foreign objects being thrown into your eyes, which can
result in severe eye damage. Before beginning power tool operation, always wear safety goggles or
safety glasses with side shields and, when needed, a full face shield. We recommend Wide Vision
Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye
protection which is marked to comply with ANSI Z87.1.
SAVE THESE INSTRUCTIONS
6
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ELECTRICAL
DOUBLE INSULATION
EXTENSION CORDS
Double insulation is a concept in safety in electric power
tools, which eliminates the need for the usual three-
wire grounded power cord. All exposed metal parts are
isolated from the internal metal motor components with
protecting insulation. Double insulated tools do not need
to be grounded.
When using a power tool at a considerable distance from
a power source, be sure to use an extension cord that has
the capacity to handle the current the tool will draw. An
undersized cord will cause a drop in line voltage, resulting in
overheating and loss of power. Use the chart to determine
the minimum wire size required in an extension cord. Only
round jacketed cords listed by Underwriter’s Laboratories
(UL) should be used.
WARNING:
When working outdoors with a tool, use an extension cord
that is designed for outside use. This type of cord is desig-
nated with “WA” on the cord’s jacket.
The double insulated system is intended to protect
the user from shock resulting from a break in the tool’s
internal insulation. Observe all normal safety precautions
to avoid electrical shock.
Before using any extension cord, inspect it for loose or
exposed wires and cut or worn insulation.
NOTE: Servicing of a tool with double insulation requires
extreme care and knowledge of the system and should be
performedonlybyaqualifiedservicetechnician. Forservice,
we suggest you return the tool to your nearest authorized
service center for repair. Always use original factory replace-
ment parts when servicing.
**Ampere rating (on tool data plate)
0-ꢀ.0
ꢀ.1-3.4 3.5-5.0 5.1-7.0 7.1-1ꢀ.0 1ꢀ.1-16.0
Cord Length
Wire Size (A.W.G.)
ꢀ5'
50'
16
16
16
16
16
16
16
16
14
16
14
1ꢀ
14
14
10
14
1ꢀ
—
ELECTRICAL CONNECTION
100'
This tool has a precision-built electric motor. It should be
connected to a power supply that is 120 volts, 60 Hz, AC
only (normal household current). Do not operate this tool
on direct current (DC). A substantial voltage drop will cause
a loss of power and the motor will overheat. If the tool does
not operate when plugged into an outlet, double-check the
power supply.
**Used on 12 gauge - 20 amp circuit.
NOTE: AWG = American Wire Gauge
WARNING:
Keep the extension cord clear of the working area.
Position the cord so that it will not get caught on lumber,
tools or other obstructions while you are working with a
power tool. Failure to do so can result in serious personal
injury.
WARNING:
Check extension cords before each use. If damaged
replace immediately. Never use tool with a damaged cord
since touching the damaged area could cause electrical
shock resulting in serious injury.
7
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FEATURES
PRODUCT SPECIFICATIONS
Depth of Cut..................................................................ꢀ in.
Collet..........................................................................1/4 in.
Peak Horsepower.................................................... 1.5 HP
No Load Speed ...................................ꢀ5,000 r/min (RPM)
Input ...................................... 1ꢀ0 V, 60 Hz, AC only, 8.5 A
ON/OFF
SWITCH
LOCk LEvEr
SPINDLE LOCk
DEPTH
aDjuSTmENT kNOb
CHIP SHIELD
LED
WOrkLIgHTS
quICk
rELEaSE buTTON
HaNDLE
Fig. 1
8
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FEATURES
kNOW yOUR ROUTER
ERGONOMIC DESIGN
The design of this tool provides easy handling when operat-
ing in different positions and at different angles.
See Figure 1.
The safe use of this product requires an understanding of
the information on the tool and in this operator’s manual as
well as a knowledge of the project you are attempting. Before
use of this product, familiarize yourself with all operating
features and safety rules.
LED WORkLIGHTS
The LED worklights, located on the bottom of the router mo-
tor, illuminate when the ON/OFF switch is on. This provides
extra light for increased visibility.
CHIP SHIELD
Aclearplasticchipshieldisinstalledonthefrontoftherouter
for protection against flying dust and chips. The shield is
designed to fit the opening of the router base.
QUICk RELEASE BUTTON
Quick depth adjustments can be made using the quick
release button.
DEPTH ADJUSTMENT kNOB
SPINDLE LOCk
The depth adjustment knob measures changes of depth
in increments of 1/1ꢀ8 in. The zero reset feature allows for
accurate depth of cut adjustments.
A spindle lock secures the spindle so that only one wrench
is needed to loosen the collet nut and change cutters.
ASSEMBLy
UNPACkING
This product has been shipped completely assembled.
WARNING:
Carefully remove the tool and any accessories from the
box. Make sure that all items listed in the packing list are
included.
If any parts are damaged or missing do not operate
this tool until the parts are replaced. Failure to heed this
warning could result in serious personal injury.
Inspect the tool carefully to make sure no breakage or
damage occurred during shipping.
WARNING:
Do not discard the packing material until you have care-
Do not attempt to modify this tool or create accesso-
ries not recommended for use with this tool. Any such
alteration or modification is misuse and could result in a
hazardous condition leading to possible serious personal
injury.
fully inspected and satisfactorily operated the tool.
If any parts are damaged or missing, please call
1-800-5ꢀ5-ꢀ579 for assistance.
PACkING LIST
R163 Router
Bag
WARNING:
Wrench
Do not connect to power supply until assembly is
complete. Failure to comply could result in accidental
starting and possible serious personal injury.
Operator’s Manual
9
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OPERATION
aDjuSTmENT bar
WARNING:
SPINDLE LOCk
Do not allow familiarity with tools to make you care-
less. Remember that a careless fraction of a second is
sufficient to inflict serious injury.
WARNING:
Always wear safety goggles or safety glasses with side
shields when operating power tools. Failure to do so
could result in objects being thrown into your eyes
resulting in possible serious injury.
LOCk
LEvEr
APPLICATIONS
You may use this tool for the purposes listed below:
Rout grooves, carve designs, mortise door jambs, and
create joints in wood and wood products
TO
Cabinet making, routing counter tops, and finishing work
uNLOCk
in wood and wood products
aDjuSTmENT
SLOT IN
mOTOr
bar Tab
mOTOr
REMOVING/INSTALLING ROUTER BASE
See Figure 2.
arrOW ON
mOTOr
To remove the base:
Unplug the router.
Place the router upside down with the Ryobi label away
from you.
Loosen the lock lever on the base.
NOTE: It should not be possible to move the router
motor with the lock lever tightened and the motor cor-
rectly installed in either base. If movement is possible
with the lock lever tightened in either of the bases, an
adjustment to the lock lever needs to be made. See
Adjustments.
arrOW
ON baSE
Hold the handles and pull the adjustment bar from the
slot in the motor base.
Fig. ꢀ
Lift the base up from the slot until the adjustment bar tab
passes out of the slot area.
To install the base:
After the tab has cleared the slot, release the adjustment
bar and press the spindle lock down and in (until it fully
locks in the collet spindle) so that it slides behind the
base housing.
Unplug the router.
With the base right side up, loosen the lock lever.
Push the spindle lock in, holding it into place.
Align arrow on base with arrow on motor.
NOTE: When using the spindle lock for any applica-
tion, make sure that the latch goes all the way in. If the
latch is depressed and does not go all the way in, turn
the collet with the wrench provided until the spindle lock
locks into place.
Push the base until it lodges into the motor housing. The
spindle lock can be released once the motor slides down
into the base. It will disengage once it has cleared the
inside of the base. Use caution as forcing may result in
permanent damage to the locking mechanism.
Pull the base until it dislodges from the motor. Use cau-
tion, as forcing may result in permanent damage to the
locking mechanism.
Pull the adjustment bar.
Place the adjustment bar tab in the slot on the motor.
Tighten the lock lever.
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OPERATION
COLLET NuT
WARNING:
If the collet nut is not securely tightened, the bit may
detach during use, causing serious personal injury.
TO
LOOSEN
WARNING:
Never use bits which are larger in diameter than the open-
ing in the router subbase. These situations could cause
possible loss of control or create other hazardous condi-
tions that could cause possible serious personal injury.
TO
TIgHTEN
CAUTION:
To prevent damage to the spindle or spindle lock, always
allow motor to come to a complete stop before engaging
the spindle lock.
SPINDLE
LOCk
Fig. 3
WARNING:
LED
WOrkLIgHT
If you are changing a bit immediately after use, be careful
not to touch the collet nut, bit, or collet with your hands or
fingers. You will get burned because of the heat buildup
from cutting. Always use the wrench provided.
WARNING:
Bit continues to rotate after the router has been turned off.
To avoid injury, wait until the bit has come to a complete
stop before removing router from the workpiece.
INSTALLING/REMOVING BITS
See Figure 3.
Unplug the router.
To install the bit:
Fig. 4
Push the spindle lock down and in, holding it into
place.
LED WORkLIGHT
Loosen the collet nut and remove the bit.
See Figure 4.
I sert the bit u til it is approximately 1/8 i . to 1/4 i . away
The two LED worklights on the base of the router motor
will come on when the ON/OFF switch is in the ON (I)
position. This provides additional lighting on the surface of
the workpiece for operation in lower-light areas.
from the collet nut face.
NOTE: Make sure that the collet always clamps the shank
(non-cutting end) of the bit.
Tighten the collet nut securely by turning it clockwise with
the wrench provided.
Release the spindle lock.
To remove the bit:
Push the spindle lock down and in, holding it into
place.
Loosen the collet nut and remove the bit.
Release the spindle lock.
11
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OPERATION
SELECTING DEPTH OF CUT
DEPTH
aDjuSTmENT
kNOb
Proper depth of cut depends on several factors: the
horsepower of the router motor, the type of bit, and the type
of wood. A lightweight, low horsepower router is designed
for making shallow cuts; a router with higher horsepower is
designed for deeper cuts. Small bits, such as veining bits
with 1/16 in. cutting diameters, are designed to remove only
small amounts of wood. Large bits, such as straight-flute
bits, remove larger amounts of wood and make deeper cuts
in soft woods, such as white pine.
TO
INCrEaSE
TO
DECrEaSE
DEPTH
DEPTH
Choose a depth of cut that will not place excessive strain on
the router motor. If you need extra force or the motor speed
slows down considerably, turn off the router and reduce the
depth of cut. Then, make the cut in two or more passes.
SCaLE
When routing a groove that is too deep to safely cut in one
pass, make the cut in several passes. We recommend that
cuts be made at a depth not exceeding 1/8 in. and that
several passes be made to reach deeper cuts.
LOCk
LEvEr
SETTING DEPTH OF CUT
quICk
See Figures 5 - 6.
bIT
rELEaSE buTTON
The bit depth can be adjusted by turning the depth
adjustment knob clockwise or counterclockwise. The
depth of the cut can be read on the depth adjustment knob.
Each mark on the scale indicates a 1/1ꢀ8 in. change in
depth setting.
INDICaTOr POINT
Fig. 5
T-HaNDLE WrENCH
Unplug the router.
Loosen the lock lever.
TO
Turn the depth adjustment knob counterclockwise to
move the collet down or clockwise to move the collet
up.
DECrEaSE
DEPTH
TO
NOTE: It should not be possible to make depth
adjustments with the lock lever tightened. If depth
adjustments are possible with the lock lever tightened,
an adjustment to the lock lever needs to be made. See
Adjustments.
INCrEaSE
DEPTH
aDjuSTINg
NuT
SLOT IN
SubbaSE
When the desired depth of cut is set, tighten the lock
lever.
To use the quick release button:
Unplug the router.
Loosen the lock lever.
Press and hold the quick release button while moving the
router motor up or down in the base.
NOTE: It should not be possible to make depth
adjustments with the lock lever tightened. If depth
adjustments are possible with the lock lever tightened,
an adjustment to the lock lever needs to be made. See
Adjustments.
TO
LOCk LEvEr
LOOSEN
Fig. 6
When the desired depth of cut is set, tighten the lock
lever.
1ꢀ
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OPERATION
NOTE: To adjust the depth of cut when the router is
mounted to a router table, unplug the router, loosen the lock
lever,turnthedepthadjustmentknobuntilthebitreachesthe
desired depth of cut, and retighten the lock lever.
ON/OFF
SWITCH
When the router is mounted to a router table, depth adjust-
ments can be made easily by using a T-handle wrench.
To make through table adjustments:
Unplug the router.
Loosen the lock lever.
Insert a T-handle wrench through the hole in the router
table into the hole on the subbase, and place the end of
the wrench socket over the adjusting nut.
Turn the wrench counterclockwise to move the collet
down or clockwise to move the collet up.
NOTE: It should not be possible to make depth
adjustments with the lock lever tightened. If depth
adjustments are possible with the lock lever tightened,
an adjustment to the lock lever needs to be made. See
Adjustments.
Fig. 7
When the desired depth of cut is set, tighten the
lock lever.
WARNING:
Do not use with router tables that fail to conform to safe
woodworking practices and offer proper guarding for the
bit. Use router tables that are UL classified and identified
suitable for use with the specific router model. Failure
to comply can result in an accident causing possible
injury.
WARNING:
Only use router tables with proper guarding for the bit and
with on-board switch controlled receptacles. Failure to
use router tables with appropriate safety features could
result in serious personal injury.
TURNING THE ROUTER ON AND OFF
See Figure 7.
To turn the router on, push the switch to the (I), or ON
position. Return the switch to the (O), or OFF position when
routing operation is finished.
13
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OPERATION
OPERATING THE ROUTER
When routing straight cuts across a workpiece, clamp a
straight edge to the workpiece to use as a guide.
STraIgHT
EDgE
NOTE: Edge guides for the router are also available. See
Accessories.
Position the straight edge parallel to the line of cut and offset
the distance between the cutting edge of the bit and the edge
of the router base. Hold the router base against the straight
edge and rout the groove.
When routing a groove wider than the diameter of the bit,
clamp a straight edge on both sides of the cut lines. Position
both guides parallel to the desired line of cut and spaced
equal distances from the desired edges of the groove. Rout
along one guide then reverse direction and rout along the
other guide. Clean out any remaining waste in the center of
the groove.
When routing a groove, the travel should be in a direction
that places the guide you are using at the right-hand side.
When the guide is positioned as shown in the “guide inside”
illustration, tool travel should be from left to right and coun-
terclockwise around curves. When the guide is positioned as
shown in the “guide outside” illustration, tool travel should
be from right to left and clockwise around curves. If there is a
choice, the first setup is generally the easier to use. In either
case, the sideways thrust you use is against the guide.
CLamP
WOrkPIECE
Fig. 8
STraIgHT
EDgE
INTERNAL ROUTING
See Figure 8.
CLamP
Tilt router and place on workpiece without the bit contact-
ing the workpiece.
Tur the router o a d let the motor build up to full
speed.
Gradually feed bit i to the workpiece u til the subbase
is level with the workpiece.
Upo completio of the cut, tur the router off a d let the
bit come to a complete stop before removing the router
from the workpiece.
EDGE ROUTING
See Figure 9.
Clamp a straight edge to the workpiece as a guide.
Place the router o the edge of the workpiece without
WOrkPIECE
the bit contacting the workpiece.
Fig. 9
Tur router o a d let the motor build up to full speed.
Gradually feed the bit i to the workpiece usi g the
clamped straight edge as a guide.
Upo completio of the cut, tur the router off a d let the
bit come to a complete stop before removing the router
from the workpiece.
14
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OPERATION
WARNING:
Do not use large router bits for freehand routing. Use of
large router bits when freehand routing could cause loss
of control or create other hazardous conditions that could
result in personal injury. If using a router table, large bits
should be used for edging only.
FREEHAND ROUTING
See Figure 10.
When used freehand, the router becomes a flexible and
versatile tool. This flexibility makes it possible to easily rout
signs, relief sculptures, etc. When freehand routing:
Draw or layout the patter o the workpiece.
Choose the appropriate bit.
NOTE: A core box or V-groove bit is often used for rout-
ing letters and engraving objects. Straight bits and ball
mills are often used to make relief carvings. Veining bits
are used to carve small, intricate details.
Fig. 10
Rout the pattern in two or more passes. Make the first
pass at ꢀ5% of the desired depth of cut. This will pro-
vide better control as well as being a guide for the next
pass.
rOuTEr
WOrk
NOTE: Do not rout deeper than 1/8 in. per pass.
EDGING WITH PILOT BIT
See Figure 11.
The arbor-type bits with pilots are excellent for quick, easy,
edge shaping of any workpiece edge that is either straight
or curved at a curvature as great or greater than the radius
of the bit to be used. The pilot prevents the bit from mak-
ing too deep a cut; and holding the pilot firmly in contact
with the workpiece edge throughout prevents the cut from
becoming too shallow.
PILOT
TOP EDgE SHaPINg
rOuTEr
guIDE
WOrk
Whenever the workpiece thickness together with the desired
depth of cut (as adjusted by router depth setting) are such
that only the top part of the edge is to be shaped (leaving
at least a 1/16 in. thick uncut portion at bottom), the pilot
can ride against the uncut portion, which serves to guide it.
However, if the workpiece is too thin or the bit set too low
so that there will be no uncut edge to ride the pilot against,
an extra board to act as a guide must be placed under the
workpiece. This “guide” board must have exactly the same
contour— straight or curved—as the workpiece edge. If it is
positioned so that its edge is flush with the workpiece edge,
the bit will make a full cut (in as far as the bit radius). On the
other hand, if the guide is positioned as shown in figure 11
(out from the workpiece edge), the bit will make less than a
full cut — which will alter the shape of the finished edge.
PILOT
WHOLE EDgE SHaPINg
Fig. 11
NOTE: Any of the piloted bits can be used without a pilot for
edge shaping with guides, as preceding. The size (diameter)
of the pilot that is used determines the maximum cut width
that can be made with the pilot against the workpiece edge
(the small pilot exposes all of the bit; the large one reduces
this amount by 1/16 in.).
15
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OPERATION
DIRECTION OF FEED AND THRUST
See Figures 12 - 13.
6
5
The router motor and bit revolve in a clockwise direction. This
gives the tool a slight tendency to twist in a counterclockwise
direction, especially when the motor revs up.
3
PrOPEr
CuTTINg
SEquENCE
Feed the router into the workpiece from left to right. When
fed from left to right, the rotation of the bit pulls the router
against the workpiece. If fed in the opposite direction, the
rotation of the spinning bit will tend to throw the router away
from the workpiece causing kickback. This could cause you
to lose control of the router.
2
4
1
7
8
Because of the high speed of bit rotation during a proper
feeding operation, there is very little kickback under normal
conditions. However, if the bit strikes a knot, hard grain,
or foreign object that affects the normal progress of the
cutting action, there will be a slight kickback. The direction
of kickback is always in the direction opposite bit rotation.
This will affect the trueness of the cut.
1/4 in. to 1 in.
Fig. 1ꢀ
THruST
guIDE INSIDE
rOTaTION
To guard against kickback, plan the setup and direction of
feed so that you will always be thrusting the tool in the same
direction that the leading edge of the bit is moving. The thrust
should be in a direction that keeps the sharp edges of the
bit continuously biting straight into new (uncut) wood.
guIDE
rOTaTION
NOTE: For best results, make sure to take enough time to
set up for cutting. While cutting, make sure to use the proper
rate of feed.
FEED
guIDE OuTSIDE
PROPER RATE OF FEED
Professional routing depends upon careful setup and proper
rate of feed which is learned through practice and use. The
proper rate of feed is dependent upon:
rOTaTION
THruST
hardness and moisture content of the workpiece
depth of cut
cutting diameter of the bit
rOTaTION
When cutting shallow grooves in soft woods such as pine, a
faster rate of feed can be used. When making cuts in hard-
woods such as oak, a slower rate of feed is required.
FEED
guIDE
Several factors will help you select the proper rate of feed.
Fig. 13
Choose the rate that does not slow down the motor.
Choose the rate at which the bit adva ces firmly a d
surely to produce a continuous spiral of uniform chips
or a smooth edge.
Testacutonascrappieceoftheworkpiecebeforeyoubegin.
Always grasp and hold the router firmly with both hands.
Listen to the sound of the motor. A high-pitched sound
means you are feeding too slowly. A strained, lower
pitched sound signals force feeding.
If you are making a small diameter, shallow groove in soft,
dry wood, the proper feed rate may be determined by the
speed at which you can travel the router along the guide line.
If the bit is a large one, the cut is deep, or the workpiece is
hard to cut, the proper feed may be a very slow one. A cross
grain cut may require a slower pace than an identical with
grain cut in the same workpiece.
Check the progress of each cut. Too slow feedi g ca
cause the router to take off in a wrong direction from the
intended line of cut. Force feeding increases the strain
of holding the tool and results in loss of speed.
Notice the chips being produced as you cut. If the router
is fed too slowly, it will scorch or burn the wood. If fed
too fast, it will take large chips out of the wood and leave
gouge marks.
16
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OPERATION
FEEDING TOO FAST
See Figure 14.
Clean, smooth routing and edge shaping can be done only
when the bit is revolving at a relatively high speed and is
taking very small bites to produce tiny, cleanly severed chips.
If you force the router to move forward too fast, the RPM of
the bit becomes slower than normal in relation to its forward
movement. As a result, the bit must take bigger bites as it
revolves. Bigger bites mean bigger chips and a rougher
finish. Also, because bigger bites require more power, the
router motor may become overloaded.
TOO FaST
Under extreme force-feeding conditions, the relative RPM
of the bit can become so slow—and the bites it has to take
so large—that chips will be partially knocked off (rather
than fully cut off). This causes splintering and gouging of
the workpiece.
Fig. 14
The router is an extremely high-speed tool, and will make
clean, smooth cuts if allowed to run freely without the over-
load of a forced feed. You can always detect force feeding
by the sound of the motor. Its high-pitched whine will sound
lower and stronger as it loses speed. Also, the strain of hold-
ing the tool will be noticeably increased.
FEEDING TOO SLOW
See Figure 15.
It is possible to spoil a cut by moving the router forward too
slowly. When you advance the router into the work too slowly,
the revolving bit does not dig into new wood fast enough
to take a bite; instead, it merely scrapes away sawdust-like
particles. Scraping produces heat, which can glaze, burn,
or mar the cut and in extreme cases, can overheat the bit,
destroying its hardness.
TOO SLOW
Fig. 15
When the bit is scraping instead of cutting, controlling the
router is more difficult. With practically no load on the mo-
tor, the bit revolves at close to top RPM, and has a much
greater than normal tendency to bounce off the sides of
the cut (especially if the wood has a pronounced grain with
hard and soft areas). As a result, the cut produced may have
rippled, instead of straight, sides.
Feeding too slowly can also cause the router to take off in a
wrong direction from the intended line of cut. Always grasp
and hold the router firmly with both hands when routing.
You can detect when you are feeding the router too slowly by
the runaway, high-pitched sound of the motor or by feeling
the wiggle of the bit in the cut.
17
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OPERATION
DEPTH OF CUT
See Figures 16 - 17.
Depth of cut is important because it affects the rate of feed
that, in turn, affects the quality of the cut and the possibility
of damage to the tool’s motor and bit.
DEPTH
OF CuT
WIDTH OF CuT
A deep cut requires a slower feed than a shallow one. A cut
that is too deep will slow the feed so that the bit is scraping
rather than cutting. A too deep cut can cause smaller bits
to be broken off. Bits that are 1/16 in. in diameter are easily
broken off when subjected to too much side thrust. A large
enough bit is not likely to break, but attempting a cut that
is too deep may result in a rough cut, and it may be difficult
to guide and control the bit as desired. It is recommended
that you do not exceed 1/8 in. depth of cut in a single pass,
regardless of the bit size or the softness or condition of the
workpiece.
Fig. 16
2ND
PaSS
1ST
PaSS
1ST
PaSS
2ND
PaSS
To make deeper cuts, make as many successive passes as
needed, lowering the bit 1/8 in. for each new pass. To save
time, perform all the cutting necessary at one depth setting
before lowering the bit for the next pass. This will insure a
uniform depth when you complete the final pass.
NOTE: Do not remove more than 1/8 in. in a single pass.
Excessive depth of cut can result in loss of control and the
possibility of serious personal injury.
Fig. 17
ADJUSTMENTS
ADJUSTING LOCk LEVER TENSION
See Figure 18.
Over time and with repeated use, the lock lever may
become loose. When this occurs, tighten the stop nut
slightly. The elastic stop nut should be loose enough so
that there is some play in the lock lever when it is in
the open position.
LOCk LEvEr
NOTE: Do not over tighten the elastic stop nut. The lock lever
should clamp tightly to secure the motor housing.
CAUTION:
Make sure the motor housing does not move up or down
when clamped. If motor is not securely clamped in base,
adjustments will not be accurate.
TO TIgHTEN
STOP NuT
Fig. 18
18
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MAINTENANCE
Electrictoolsusedonfiberglassmaterial,wallboard,spackling
WARNING:
compounds, or plaster are subject to accelerated wear and
possible premature failure because the fiberglass chips and
grindingsarehighlyabrasivetobearings,brushes,commuta-
tors, etc. Consequently, we do not recommended using this
toolforextendedworkonthesetypesofmaterials. However,
if you do work with any of these materials, it is extremely
important to clean the tool using compressed air.
When servicing, use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
WARNING:
LUBRICATION
Always wear safety goggles or safety glasses with side
shields during power tool operation or when blowing
dust. If operation is dusty, also wear a dust mask.
All of the bearings in this tool are lubricated with a sufficient
amount of high grade lubricant for the life of the unit under
normal operating conditions. Therefore, no further lubrica-
tion is required.
GENERAL MAINTENANCE
CLEANING THE BITS
Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use. Use
clean cloths to remove dirt, dust, oil, grease, etc.
Get faster, more accurate cutting results by keeping
bits clean and sharp. Remove all accumulated pitch and
gum from bits after each use. When sharpening bits, sharpen
only the inside of the cutting edge. Never grind the outside
diameter. When sharpening the end of a bit, be sure to grind
the clearance angle the same as originally ground.
WARNING:
Do not at any time let brake fluids, gasoline, petroleum-
based products, penetrating oils, etc., come in contact
with plastic parts. Chemicals can damage, weaken or
destroy plastic which may result in serious personal
injury.
CLEANING THE COLLET
Dust and chips may collect on the collet from time to time,
making it necessary to clean the collet. To do so, remove
the collet assembly and wipe it with a clean, dry rag. Clean
the taper in the shaft in the same manner. Never immerse
the collet or end of the shaft in a solvent or in water. Before
replacing the collet assembly, put a drop of SAE30 motor
oil on the inside of the nut, on the treads of the shaft, and
on the taper in the shaft. Replace the collet assembly onto
the shaft by hand only. Never tighten the collet nut without
a bit in the collet. This action could permanently damage
the collet.
ACCESSORIES
Look for these accessories at the service center:
Edge Guide.......................................................................................................................................................6090080-1
ꢀ5 pc. Carbide Router Bit Kit .............................................................................................................................Aꢀ5RSꢀ5
1ꢀ pc. Carbide Router Bit Kit .............................................................................................................................Aꢀ5RS1ꢀ
8 pc. Starter Carbide Router Bit Kit ...................................................................................................................Aꢀ5RS08
WARNING:
Current attachments and accessories available for use with this tool are listed above. Do not use any attachments or
accessories not recommended by the manufacturer of this tool. The use of attachments or accessories not recommended
can result in serious personal injury.
19
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OPERATOR’S MANUAL
FIXED BASE ROUTER
DOUBLE INSULATED
R163
WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities con-
tains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are:
•lead from lead-based paints,
•crystalline silica from bricks and cement and other masonry products, and
•arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,
such as those dust masks that are specially designed to filter out microscopic particles.
• SERVICE
Now that you have purchased your tool, should a need ever exist for repair parts or service,
simply contact your nearest Authorized Service Center. Be sure to provide all pertinent
facts when you call or visit. Please call 1-800-5ꢀ5-ꢀ579 for your nearest Authorized
list of Authorized Service Centers.
• MODEL NO. AND SERIAL NO.
The model number of this tool will be found on a plate attached to the motor housing.
Please record the model number and serial number in the space provided below.
• HOW TO ORDER REPAIR PARTS
When ordering repair parts, always give the following information:
R163
• MODEL NUMBER
• SERIAL NUMBER
Ryobi® is a registered trademark of Ryobi Limited used under license.
ONE WORLD TECHNOLOGIES, INC.
14ꢀ8 Pearman Dairy Road, Anderson, SC ꢀ96ꢀ5
Phone 1-800-5ꢀ5-ꢀ579
983000-958
06-18-07 (REV:01)
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